lifting crane_om thern 5110_5124

Read this Own ers Man u al thor ough ly be fore op er at ing the equip ment. Keep it with the equip ment at all times. Re place ments are avail able from Thern, Inc., PO Box 347, Winona, MN 55987,507-454-2996.www.thern.com

Owners Man ualFor 5110 and 5124 Series Portable Davit Cranes

IMPORTANT: Please record product information on page 2. This information is re quired when calling the fac to ry for service.

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Owner's Manual for Thern 5110 and 5124 Series Portable Davit Cranespage 2

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Two-Year Limited WarrantyThern, Inc. warrants its products against defects in material or workmanship for two years from the date of purchase by the original using buyer, or if this date cannot be established, the date the product was sold by Thern, Inc. to the dealer. To make a claim under this warranty, contact the factory for an RGA number. The product must be returned, prepaid, directly to Thern, Inc., 5712 Industrial Park Road, Winona, Minnesota 55987. The following information must accompany the product: the RGA number, the date of purchase, the description of the claimed defect, and a com-plete explanation of the circumstances involved. If the product is found to be defective, it will be repaired or replaced free of charge, and Thern, Inc. will reimburse the shipping cost within the contiguous USA.

This warranty does not cover any damage due to accident, misuse, abuse, or negligence. Any alteration, repair or modifi cation of the product outside the Thern, Inc. factory shall void this warranty. This warranty does not cover any costs for removal of our product, downtime, or any other incidental or consequential costs or damages resulting from the claimed defects. This warranty does not cover brake discs, wire rope or other wear components, as their life is subject to use conditions which vary between applications.

FACTORY AUTHORIZED REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY TO THE CONSUMER. THERN, INC. SHALL NOT BE LIABLE FOR ANY INCIDEN-TAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THIS PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW, ANY IMPLIED WAR-RANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THIS PRODUCT IS LIMITED IN DURATION TO THE DURATION OF THIS WARRANTY.

Some states do not allow the exclusion or limitation of incidental or consequential damages, or allow limitations on how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. This warranty gives you specifi c legal rights, and you may also have other rights which vary from state to state.

Note: Thern, Inc. reserves the right to change the design or discontinue the production of any product without prior notice.

About This ManualThe Occupational Safety and Health Act of 1970 states that it is the employers re spon si bil i ty to provide a workplace free of hazard. To this end, all equipment should be installed, operated, and maintained in compliance with applicable trade, industrial, federal, state, and local regulations. It is the equipment own er's re spon -si bil i ty to ob tain copies of these regulations and to determine the suit abil i ty of the equip ment to its intended use.

This Owners Manual, and warning labels attached to the equip ment, are to serve as guidelines for hazard-free installation, op er a tion, and maintenance. They should not be understood to prepare you for every pos si ble situation.

The information contained in this manual is applicable only to the Thern 5110 and 5124 Series Portable Davit Cranes. Do not use this manual as a source of in for -ma tion for any other equip ment.

The following symbols are used for emphasis throughout this man u al:

Failure to follow WARNING! instructions may result in equipment dam age, property damage, and/or serious personal injury.

Failure to follow CAUTION! instructions may result in equipment damage, prop er ty damage, and/or minor personal injury.

Important!

Failure to follow important! instructions may result in poor per for mance of the equipment.

Please record the following:Date Purchased:

Crane Model No.:

Crane Serial No.:

If sold with a winch:Winch Model No.:

Winch Serial No.:

This information is required when calling the factory for service.

Owner's Manual for Thern 5110 and 5124 Series Portable Davit Cranes page 3

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Suggestions for Safe Operation

DO the following:

Read and comply with the guidelines set forth in this Owners Manual. Keep this manual, and all labels attached to the crane, readable and with the equip-ment at all times. Contact Thern, Inc. for replacements.

Check lubrication before use.

Install the wire rope securely to the winch drum.

Keep at least 4 wraps of wire rope wound on the drum at all times, to serve as anchor wraps. With less than 4 wraps on the drum the wire rope could come loose, causing the load to escape.

Keep hands away from sheaves, gears, wire rope, and other moving parts of the equipment.

Disconnect electric power before servicing the equipment.

Keep all unnecessary personnel away from crane while in operation. Keep out of the path of the load, and out of the path of a broken wire rope that might snap back and cause injury.

DO NOT do the following:

Do not lift people, or things over people. Do not walk or work under a load or in the line of force of any load.

Do not exceed the load rating of the crane or any other component in the system. To do so could result in failure of the equipment.

Do not use more than one crane to move a load that exceeds the load rating of a single crane. A shift in load weight could overload the equipment.

Do not use damaged or malfunctioning equipment. To do so could result in failure of the equipment.

Do not modify the equipment in any way. To do so could cause equipment failure.

Do not wrap the wire rope around the load. This damages the wire rope and could cause the load to escape. Use a sling or other approved lifting device.

Do not operate the crane with guards removed or improperly installed.

Do not divert your attention from the operation. Stay alert to the possibility of accidents, and try to prevent them from happening.

Do not jerk or swing the load. Avoid shock loads by starting and stopping the load smoothly. Shock loads overload the equipment and may cause damage.

Do not use the crane and winch components for any use other than for their original intended function.

Do not use the crane to drag or pull loads. This will create side pulls, which could damage the equipment or cause the load to tip.

Do not leave a suspended load unattended. Place the load on the ground if it must be left unattended.

Do not adjust the winch brake with the load suspended.


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Important!

A qualifi ed professional should inspect or design the founda-tion to insure that it will provide adequate support.

Locate the crane so it will be vis-ible during the entire op er a tion.

1.1 Installing the Crane

Do not install the crane in an area defi ned as hazardous by the National Electric Code, unless installation in such an area has been thoroughly approved.

Do not install the crane near corrosive chemicals, fl ammable materials, ex-plosives, or other elements that may damage the crane or injure the operator. Adequately protect the crane and the operator from such elements.

Position the crane so the operator can stand clear of the load, and out of the path of a broken wire rope that could snap back and cause injury.

Attach the crane to a rigid and level foundation that will support the crane and its load under all load conditions, including shock loading.

1.1.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on installing the equipment.

1.1.2 LOCATE THE CRANE in an area clear of traffic and obstacles that could interfere with operation. Make sure the crane is accessible for maintenance and operation.

1.1.3 INSTALL THE CRANE on a level surface. An uneven surface may cause the boom to rotate in the direction the mast is leaning.

1.1.4 FASTEN THE BASE securely to the foundation to withstand applicable overturning moments and mounting bolt reaction. See Table 1.

a FOR STANDARD PRODUCTS referred to in this manual, use 5/8 - inch coarse thread fasteners, grade 5 or better. Torque for Grade 5 fasteners with-out lubrication is 150 ft lb. Make sure mounting holes are secured to a solid foundation able to support the crane and the load under all conditions with design factors based on accepted engineering practices.

b NON-STANDARD PRODUCTS that vary from the original design may have different fastening requirements. Contact a structural engineer or Thern, Inc. for this information.

TO COMPLY WITH LOCAL CODES, CONTACT A QUALIFIED PROFES-SIONAL TO OBTAIN PROPER STRUCTURE OR FOUNDATION SPECIFI-CATIONS FOR THE MOUNTING OF THERN PRODUCTS.

Pedestal Wall-Mount Base Only Base OnlyCrane Mast Suggested Axial Force1 Axial Force1 Shear Force Model Moment Bolt Size (Crane at 45) Per Bolt Per Bolt5110 36,000 in-lb 5/8 inch 1,756 lb 1,241 lb 1,127 lb

5124 91,200 in-lb 5/8 inch 4,447 lb 3,145 lb 2,601 lb1 Force in tension

Table 1 Crane Reactions


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Important!

Inspect the crane during as sem bly according to the Instructions for Periodic Inspection. This will give you a record of the con di tion of the crane with which to com-pare future inspections.

Save all boxes and crates that the crane was shipped in, use them again if you need to repackage the crane.

Contact the factory immediately if any parts are missing or dam aged.

Do not overtighten fasteners, this may strip threads or cause dam-age to other parts.

1.2 Assembling the Crane

When installing the ratchet jack, support the end of the boom so the boom does not fall and the ratchet jack does not swing up causing damage or injury.

When installing the boom extension, hold the boom extension securely so it does not slide abruptly in or out of the boom causing damage or injury.

1.2.1 STUDY PARTS DRAWINGS to understand how the crane is assembled. See pages 18-22.

1.2.2 LUBRICATE PINS and other components prior to assembly. See Section 3.2 Lubricating the Crane.

1.2.3 INSTALL THE BASE and then assemble the crane in the following order.

a INSTALL THE MAST in the base. Move the mast side to side to make sure the bottom of the mast properly seats on the pin in the bottom of the base.

b FASTEN THE BOOM to the mast using the clevis pin and lynch pin pro-vided. Make sure the boom is positioned correctly, with the carrying handles located on the same side as the handles on the mast.

c INSTALL THE RATCHET JACK by fastening one end of the ratchet jack to the ears on the boom with the clevis and lynch pin provided. Carefully pivot the boom up until the other end of the ratchet jack aligns with the ears on the mast, and secure the ratchet jack to the mast using the clevis pin and lynch pin provided.

d ADJUST THE BOOM with the ratchet jack so the boom is just slightly above horizontal.

e SLIDE THE BOOM EXTENSION into the boom, and secure in place with the clevis pin and lynch pin provided. Make sure the boom extension is posi-tioned correctly with the boom ears positioned up. See assembly drawings.

f POSITION THE SHEAVE between the ears on the boom extension, and fasten in place with the clevis pin and cotter pin provided.

g INSTALL THE CLEVIS PIN in the holes located above the sheave at the end of the boom. Secure in place with the hair cotter pin provided.

h INSTALL THE HANDLE on the lower end of the boom, using the clevis pin and lynch pin provided.

1.2.4 FASTEN THE WINCH to the mounting plate on the boom using the fasteners provided. On some models you will need to use the winch adapter plate and fasten-ers provided to fasten the winch to the crane. Make sure the winch is positioned correctly with the winch drum facing forward toward the boom extension.

1.2.5 INSTALL THE WINCH HANDLE on hand winches, or connect electric cur-rent on power winches. Refer to instructions in the Winch Owners Manual.

1.2.6 INSTALL THE WIRE ROPE. Use wire rope assemblies in the length specifi ed on page 23.

a PASS THE WIRE ROPE over the sheave at the end of the boom.

b ANCHOR THE WIRE ROPE to the winch drum and wind 4 wraps of wire rope onto the drum to act as anchor wraps. Refer to the instructions in the Winch Owners Manual.

1.2.7 MAKE SURE ALL LYNCH PINS ARE PROPERLY INSTALLED, and cotter pins properly bent to secure them in place. See fi gure 1.

Figure 1 Cotter Pins

bend arms back


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2.1 General Theory of Operation2.1.1 THE FORCE REQUIRED to lift the load must not exceed the load rating of

the crane. Consider the total force required to lift the load, not the weight of the load.

2.1.2 THIS EQUIPMENT CAN develop forces that will exceed the load rating. It is the responsibility of the equipment user to limit the size of the load. Inspect the equipment regularly for damage according to the instructions contained in this manual.

2.1.3 PERFORMANCE RATINGS of the equipment are affected by the position of the boom, the amount of wire rope you use and whether you use a single or two part line. Two-part line not available on the 5110 Series. See the Performance Characteristics Tables on page 23.

a LOAD RATING represents the maximum force that can be placed on new equipment. Load ratings are assigned values for specifi c boom positions, wire rope lengths, and rigging confi gurations (single or two part line). Crane load ratings decrease as you extend the boom, and increase with two-part line. Two-part line not available on 5110 Series. See the Perfor-mance Characteristics Tables page 23.

b LIFT varies with the position of the boom, the length of the wire rope, and the rigging confi guration (single or two part line). Two-part line not avail-able on the 5110 Series.

c REACH varies with the position of the boom.

2.1.4 DUTY RATINGS refer to the type of use the equipment is subject to. Con-sider the following when determining duty rating.

a ENVIRONMENT: harsh environments include hot, cold, dirty, wet, corro-sive, or explosive surroundings. Protect the equipment from harsh envi-ronments when possible.

b MAINTENANCE: poor maintenance, meaning poor cleaning, lubrication, or inspection, leads to poor operation and possible damage of the equipment. Minimize poor maintenance by carefully following the instructions con-tained in this manual.

c LOADING: severe loading includes shock loading and lifting loads that exceed the load rating of the equipment. Avoid shock loads, and do not exceed the load rating of the equipment.

d FREQUENCY OF OPERATION: frequent or lengthy operations increase wear and shorten the life span of gears, bearings, sheaves, and other components. Increase maintenance of the equipment if used in frequent operations.

CONTACT THE FACTORY FOR MORE INFORMATION.

Important!

Limit nonuniform winding by keeping tension on the wire rope.

It is your responsibility to detect and account for different fac-tors affecting the condition and per for mance of the equipment.


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2.2 Preparing for Operation

When adjusting boom length, set the boom angle just above horizontal and hold the boom extension securely so it does not slide abruptly in or out of the boom causing damage or injury.

When adjusting the boom angle, raise the rotation handle with one hand and operate the ratchet jack with the other to avoid jamming the handles and causing damage or injury.

2.2.1 CONSIDER THE OPERATION. Do not begin until you are sure you can perform the entire operation without hazard.

2.2.2 INSPECT ALL COMPONENTS of the system.

a INSPECT THE CRANE and other equipment according to the Instructions for Frequent Inspection.

b INSPECT THE WINCH according to the instructions in the Winch Owners Manual.

c OPERATORS must be in good health, alert, thoroughly trained in operat-ing the equipment, and properly clothed (hard hat, safety shoes and safety glasses, no loose clothing).

d THE LOAD must be clear of other objects and free to move. Make sure the load will not tip, spin, roll away, or in any way move uncontrollably.

2.2.3 KNOW YOUR LOAD and make sure you do not exceed the load rating of the crane or any other equipment in the system.

2.2.4 POSITION THE BOOM so the load hook is centered over the load. Avoid side pulls which could damage the crane or cause the load to tip. See fi gure 2.

a ADJUST BOOM LENGTH by moving the boom extension in or out. The load rating decreases as you increase boom length. See the Performance Characteristics Tables page 23.

b ADJUST BOOM ANGLE by operating the ratchet jack to raise or lower the boom. The lift height below base level decreases as you raise the boom. See the Performance Characteristics Tables page 23.

2.2.5 CONFIGURE THE CRANE for single part or two-part line operation. Load ratings may increase with two-part line, lift height below base level will decrease with two part line. Two part line not available on 5110 Series. See the Performance Characteristics Tables page 23. Study parts draw-ings on pages 18-22.

Figure 2 Positioning the Boom

center line

center line

correct

incorrect

Important!

Start an inspection program as soon as you put the crane into use.

Appoint a qualifi ed person to be responsible for regularly in spect ing the equipment.

Keep written records of inspec tion. This allows comparison with com ments from previous inspec tions so you can see changes in condition or per for mance.


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2.3 Attaching the Load

Do not wrap the wire rope around the load. This damages the wire rope and could cause the load to escape. Use a sling or other approved lifting device.

2.3.1 CLEAR OBJECTS from the path of the load so you can move it freely and observe it at all times during the operation.

2.3.2 MAKE SURE THE WIRE ROPE is not twisted. A twisted wire rope could cause the load to spin when it is raised off the ground.

2.3.3 ATTACH THE LOAD using a nylon sling, or other approved lifting device. Follow the recommendations of the sling manufacturer.

a SEAT THE SLING in the saddle of the hook with the hook latch completely closed. See fi gure 3.

b CENTER THE LOAD on the hook so it will remain balanced and not tip or rotate to one side.

2.4 Moving the Load2.4.1 MOVE THE LOAD slowly and smoothly, only a small distance at first.

Make sure the load is balanced and securely attached before continuing.

2.4.2 OPERATE THE WINCH to raise or lower the load. Refer to the instructions in the Winch Owners Manual.

2.4.3 OBSERVE THE WIRE ROPE as it winds onto the drum. If it becomes loose, uneven, or overlapped, stop the operation and rewind the wire rope before continuing. Continued operation with overlapped or uneven wire rope can damage the wire rope and shorten its life.

2.4.4 OPERATE THE RATCHET JACK if necessary, to adjust the angle of the boom to keep the sheave centered over the load.

2.4.5 ROTATE THE BOOM to move the load side-to-side.

a ROTATE THE BOOM slowly and smoothly to avoid swinging the load or causing shock loads. Do not jam the boom against other objects.

b USE THE HANDLE to rotate the boom. Do not push or pull the load or the wire rope to rotate the boom.

Figure 3 Attaching Load

latch closed tight against

hook

sling seated in saddle of hook

Important!

Obey a stop signal from anyone.

Maintain tension on the wire rope to keep it tightly and evenly wound on the drum.

If the crane and load are not vis-ible during the entire op er a tion, get help from another person.

Appoint a supervisor if more than one person is involved in the operation. This will reduce con fu sion and increase safety.

When lifting a load, use a tag line to keep the load from swing ing or twisting, while keeping yourself away from the load.


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3.1 Cleaning the Crane Clean the crane to remove dirt and help prevent rust and corrosion.

3.1.1 CLEAN THE CRANE every six months or whenever it is dirty.

a WIPE ALL EQUIPMENT to remove dirt and grease.

b LEAVE A LIGHT FILM of oil on all surfaces to protect against rust and corro sion.

c WIPE OFF excessive amounts of oil to avoid the accumulation of dirt.

3.1.2 REMOVE UNNECESSARY OBJECTS from the area surrounding the crane.

Important!

Increase the frequency of main te-nance procedures if the crane is:

Operated for long periods.

Used to lift heavy loads.

Operated in wet, dirty, hot, or cold surroundings.


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3.2 Disassembling the Crane

When removing the boom extension, hold the boom extension securely so it does not slide abruptly in or out of the boom causing damage or injury.

When removing the ratchet jack, support the end of the boom so the boom does not fall and the ratchet jack does not swing up causing damage or injury.

3.2.1 REMOVE ANY ATTACHED LOAD from the wire rope.

3.2.2 REMOVE THE WIRE ROPE

a REMOVE THE ROPE KEEPER CLEVIS PIN located at the end of the boom.

b UNWIND THE ROPE from the winch drum and release the anchor.

c REPLACE THE ROPE KEEPER CLEVIS PIN

3.2.3 REMOVE THE WINCH HANDLE on hand winches, or disconnect electric current on power winches. Refer to instructions in the Winch Owners Manual.

3.2.4 REMOVE THE WINCH from the mounting plate.

a SECURE THE WINCH to prevent it from falling off when the fasteners are loosened.

b LOOSEN AND REMOVE the fasteners.

3.2.5 REMOVE THE ROTATION HANDLE from the back of the boom. (NOTE: Remove the rotation handle fi rst before the ratchet jack to avoid it swinging up if the boom should fall when the ratchet jack is released)

a REMOVE THE LYNCH PIN and clevis pin and remove the handle.

b REPLACE THE CLEVIS PIN and lynch pin.

3.2.6 REMOVE THE BOOM EXTENSION.

a ADJUST THE BOOM ANGLE using the ratchet jack, so the boom is just slightly above horizontal.

b SECURE THE BOOM EXTENSION then remove the lynch pin and clevis pin securing the boom extension to the boom.

c CAREFULLY PULL THE BOOM EXTENSION out of the boom, then reinstall the clevis pin and lynch pin in the boom.

3.2.7 REMOVE THE RATCHET JACK.

a SECURE THE BOOM to prevent it from falling when the ratchet jack is released.

b DISCONNECT THE RATCHET JACK at the mast ears (bottom) by remov-ing the lynch pin and clevis pin and slowly lower the boom until it is resting against the mast. Be careful that the ratchet jack does not swing up and cause injury.

c REMOVE THE PINS AT THE BOOM (top) to disconnect the ratchet jack from the crane. Hold onto the ratchet jack to prevent it from falling away.


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Important!

Make sure lubricant has a tem- per a ture rating appropriate for the ambient temperatures of the operation.

d RECONNECT the clevis pins to the boom and mast with the appropriate lynch pins.

3.2.8 DISCONNECT THE BOOM from the mast.

a SECURE THE BOOM to prevent it from falling away when the pins are removed.

b REMOVE THE LYNCH PIN AND CLEVIS PIN and carefully remove the boom.

c REPLACE the clevis pin and lynch pin in the mast.

3.2.9 REMOVE THE MAST FROM THE BASE, by lifting it out of the base.

TO REASSEMBLE THE CRANE, SEE ASSEMBLING THE CRANE, SEC-TION 1.2.

3.3 Lubricating the CraneLubricate the crane properly to help protect it from wear and rust. Read the following instructions carefully.

3.3.1 LUBRICATE ALL PINS before installation and at least every 3 months. Use a grease brush to apply a light fi lm of NLGI #2 grease to all pins.

3.3.2 LUBRICATE THE MAST BEARING before installation and at least every 3 months. Use a grease brush to apply a fi lm of NLGI #2 grease to both inside and outside surfaces.

3.3.3 LUBRICATE THE PIN BUSHING located on the bottom of the mast before installation and at least every 3 months. Use a grease brush to apply a fi lm of NLGI #2 grease to the bushing.

3.3.4 LUBRICATE THE RATCHET JACK before installation and at least every 3 months. Use a grease gun to apply an NLGI #2 grease to the grease fi ttings on the ratchet jack until excess grease can be seen.

3.3.5 LUBRICATE THE WINCH. Refer to the Winch Owners Manual for in-structions.

3.3.6 LUBRICATE THE WIRE ROPE and other equipment by following the manufacturers recommendations.


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3.3 Inspecting the Equipment

Do not use damaged or malfunctioning equipment. Place an OUT OF ORDER sign on the crane. Do not use the crane until the sign is removed by a qualifi ed maintenance person who has completely corrected the problem.

Inspect the crane to detect signs of damage or poor operation before they become hazardous. See table 2 Inspection Checklist.

3.4.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on inspecting the crane and other equipment.

3.4.2 REFER TO THE WINCH OWNERS MANUAL for information regarding winch inspection.

3.4.3 Instructions for Frequent Inspection

a VISUALLY INSPECT the entire crane and all other equipment involved in the operation.

Check all equipment for cracks, dents, bending, rust, wear, corrosion and other damage.

Make sure the wire rope is installed correctly and anchored securely.

Make sure the entire crane is properly lubricated.

Make sure all fasteners are tight and secure.

Make sure mounting fasteners are tightened securely.

Check the ratchet jack for signs of leakage or damage, and make sure it operates smoothly to raise and lower the boom.

Make sure the foundation is in good condition, and capable of supporting the crane and its load under all load conditions.

b TEST CRANE PERFORMANCE by moving a test load of 10% of rated load capacity.

Listen for unusual noises, and look for signs of damage as you operate the crane.

Make sure the wire rope winds evenly and tightly onto the drum. If it is loose or uneven, rewind it before continuing.

Make sure the load moves smoothly, without hesitation or strain.

On hand operated models, make sure the winch handle rotates freely in both directions.

On power operated models, make sure the winch responds to the control device. It must rotate as shown on the control labels, and it must turn off when you release the control.

Make sure the boom rotates freely when you push the handle, and re-mains stationary when you release it.

Check the brake. Raise the load, then lower it and stop it a few feet off the ground. If the load continues to coast or creep, the brake may be in need of repair or adjustment.

Completely correct all problems before continuing. Use the Troubleshooting Chart to help determine the cause of certain problems. See table 3.

Important!

Start an inspection program as soon as you put the crane into use.

Appoint a qualifi ed person to be responsible for regularly in spect ing the equipment.

Keep written records of inspec tion. This allows comparison with com ments from previous inspec tions so you can see changes in condition or per for mance.

Perform frequent inspections:

Before each operation.

Every 3 hours during operation.

Whenever you notice signs of damage or poor operation.


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Table 2 Inspection Checklist damages problemsgeneral fi nish weathered, fl aking, otherwise damaged equipment not properly lubricated

parts cracked, bent, rusted, worn, otherwise damaged unusual noises, other signs of malfunction

foundation loose, unstable, otherwise damaged not level - boom swerves

fasteners stripped threads, bent, worn, otherwise damaged loose, not tightened to the proper torque

boom assembly holes worn, distorted, or otherwise damaged does not rotate freely

winch assembly gears, bearings, and other parts worn, otherwise damaged winch jerks or hesitates under load

brake corroded, cracked, worn, otherwise damaged brake does not operate properly

sheaves holes worn, distorted, or otherwise damaged does not rotate freely

wire rope bent, crushed, otherwise damaged wire rope loosely or unevenly wound

broken wires, see fi gure 4

replace if more than 6 wires in one lay, number per strand =

or 3 wires in one strand in one lay, are broken number per lay =

diameter reduced, see fi gure 6

replace if diameter is excessively worn diameter =

end connections corroded, rusted, worn, otherwise damaged not securely attached

load hook twisted, bent, worn, otherwise damaged, see fi gure 5 hook latch fails to close when released

replace if twist is 10 degrees or more twist =

replace if throat width is 15% larger than nominal throat width =

replace if thickness is 10% less than nominal thickness =

labels and plates dirty, illegible, otherwise damaged loosely attached or missing

comments:

authorized signature: date

checked boxes indicate damage or problem in need of repair


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Figure 5 Load Hook Inspection

throat opening

twist

thick ness

The wire rope assembly must be replaced if the throat opening is 15% wider than nominal, if the thick ness is 10% less than nomi-nal, or if the hook is twisted 10 or more.

Perform periodic inspections:

Every 6 months.

Whenever you return the crane to service from storage.

Whenever you notice damage or poor operation in a frequent in spec tion.

Whenever you have, or think you may have, overloaded or shock loaded the crane.

Figure 4 Broken Wires

wire

strand

onelay

Wire rope assembly must be replaced if more than 6 wires are bro ken in one lay, or if more than 3 wires are broken in one strand in one lay.

3.4.4 Instructions for Periodic Inspection

a VISUALLY INSPECT the crane and all other equipment.

Check the fi nish for wear, fl aking, or other damage.

Check all equipment for cracks, dents, bending, rust, wear, corrosion and other damage. If the equipment was overloaded, or if you notice cracks and other signs of overloading and damage, promptly remove equipment from use and have it repaired or replaced. DO NOT CONTINUE TO USE DAMAGED OR OVERLOADED EQUIPMENT.

Check all fasteners for stripped threads, wear, bending, and other damage.

Make sure the entire crane is properly lubricated.

Check the ratchet jack for signs of leakage or damage, and make sure it operates smoothly to raise and lower the boom.

Make sure all labels and plates are readable, fi rmly attached, free of dam-age and clean. Replacements are available from the factory.

b REMOVE THE WIRE ROPE entirely from the crane.

Always wear protective clothing when handling wire rope.

Check the entire length of wire rope for bent wires, crushed areas, broken or cut wires, corrosion, and other damage. Carefully inspect areas that pass over sheaves or through roller guides.

Note the location and concentration of broken wires. Replace wire rope if more than 6 wires are broken in one lay, or more than 3 wires are broken in one strand in one lay. See fi gure 4.

Make sure the load hook or other device is securely attached to the wire rope, and the wire rope where it is attached is not frayed, corroded, bro-ken, or otherwise damaged.

Measure the throat opening, thickness, and twist of the hook. Replace the hook if it shows signs of damage. See fi gure 5.

Make sure hook latch opens without binding and closes when released.

Check the anchor holes in the drum and the surrounding area for signs of wear or distortion.

c PLACE 100 POUNDS of tension on the wire rope.

Measure the diameter of the wire rope, especially in areas where wear is noticeable. Replace the wire rope if the diameter measures below the minimum diameter at any point. See fi gure 6.

d REMOVE THE WINCH and inspect it by following the instructions in the Winch Owners Manual.

e DISASSEMBLE THE CRANE by removing the ratchet jack, the boom, and the winch. Inspect each component for damage.

f REMOVE THE CRANE BASE from the foundation.

Check fasteners for stripped threads, wear, bending, and other damage.

Check the foundation for cracks, corrosion, and other damage.


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g FASTEN THE CRANE BASE securely to the foundation.

h REASSEMBLE THE CRANE.

i TEST CRANE PERFORMANCE by operating the crane with a test load equal to the load rating.

Listen for unusual noises, and look for signs of damage as you operate the crane.

Make sure the wire rope winds evenly and tightly onto the drum. If it is loose or uneven, rewind it before continuing.

Make sure the load moves smoothly, without hesitation or strain.

On hand operated models, make sure the winch handle rotates freely in both directions.

On power operated models, make sure the winch responds to the control device. It must rotate as shown on the control labels, and it must turn off when you release the control.

Make sure the boom rotates freely when you push the handle, and re-mains stationary when you release it.

Check the brake. Raise the load, then lower it and stop it a few feet off the ground. If the load continues to coast or creep, the brake may be in need of repair or adjustment.

Completely correct all problems before continuing. Use the Troubleshooting Chart to help determine the cause of certain problems. See table 3.

Figure 6 Rope Diameter

di ame ter

in cor rectcorrect

The wire rope assembly must be replaced if the diameter mea-sures less than the minimum diameter at any point.

wire ropediameter minimum diameter

1/4 in 15/64 in (.2344 in)

5/16 in 19/64 in (.2969 in)

Table 3 Troubleshooting Chartproblem cause correctionoverheating operated too long without rest . . .. . .. . .. . . allow to cool

load too heavy . . .. . .. . .. . .. . .. . .. . .. . .. . . lighten load

poor lubrication . . .. . .. . .. . .. . .. . .. . .. . .. . . inspect and lubricate as necessary

bearing seized up . . .. . .. . .. . .. . .. . .. . .. . . inspect and replace as necessary

boom bounces up and down load too heavy . . .. . .. . .. . .. . .. . .. . .. . .. . . lighten load

mounting bolts loose . . .. . .. . .. . .. . .. . .. . . tighten mounting bolts to proper torque

sheave worn or damaged. . .. . .. . .. . .. . .. . . inspect and replace as necessary

foundation loose or unlevel . . .. . .. . .. . .. . . inspect and repair as necessary

winch gears worn or damaged . . .. . .. . .. . . inspect and repair as necessary

boom does not rotate rotation points contaminated or worn . . .. . . inspect and repair as necessary

fl ange bearing broken or locked. . .. . .. . .. . . inspect and replace as necessary

boom rotates on its own foundation loose or unlevel . . .. . .. . .. . .. . . inspect and repair as necessary

mast bent, distorted, or leaning . . .. . .. . .. . . inspect and repair as necessary

unusual noises

high pitched squeak poor lubrication . . .. . .. . .. . .. . .. . .. . .. . .. . . lubricate entire crane properly

grinding noise contaminated lubricant at rotation points . . . clean and lubricate rotation points

rattling noise loose bolts, set screws or other fasteners. . . tighten all bolts and other fasteners

Refer to the Winch Owners Manual for possible problems with the winch and brake.


A8084C-1106

Important!

It is your responsibility to de- ter mine when to replace parts. When considering whether to continue using a part or to replace it, re mem ber that re plac ing it is the best way to avoid further equipment dam age.

Appoint a qualifi ed person to be responsible for all repairs to the equipment.

3.4 Repairing the Crane3.5.1 GET FACTORY AUTHORIZATION for all repairs. Unauthorized repairs

will void the warranty, and may lead to damage or failure of the crane.

3.5.2 REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern repair parts.

3.5.3 REFINISH AREAS where the paint is worn or flaking. A good finish helps to protect against corrosion and weather damage.

a REMOVE THE FINISH from damaged areas, down to the bare metal.

b CLEAN THE AREA thoroughly.

c REPAINT with a high quality primer and finishing coat.

3.5.4 TO ORDER REPAIR PARTS, contact your local dealer. Include the follow-ing information when ordering:

model number

serial number (or code number)

part number

date purchased, and from whom

description of what happened, or what is wrong

your name and return address

Model 5110 Part Numbers Component Weight Assembly/Disassembly Weight (with pins)

Component Standard / Galvanized / Stainless LB KG LB KGMast C3857RED / C3857GAL / C3834 41 18.5 43 19.35Boom D2558RED / D2558GAL / D2553 35 16 37 16.65Boom Ext C3858RED / C3858GAL / C3835 25 11.25 26 11.7Jack C3410 / C3411 / C3411 11 5 11 5Handle B3561RED / B3561GAL / B3834 7 3 7 3 TOTAL 119 53.75 124 55.7

Model 5124 Part Numbers Component Weight Assembly/Disassembly Weight (with pins)

Component Standard / Galvanized / Stainless LB KG LB KG Mast C3385RED / C3385GAL / C3608 66 30 69 31Boom D2049RED / D2049GAL / D2270 77 35 80 36Boom Ext C3386RED / C3386GAL / C3609 46 21 47 21.2Jack C3410 / C3411 / C3411 11 5 11 5Handle B3561RED / B3561GAL / B3844 7 3 7 3 TOTAL 207 94 214 96.2

Table 4 Crane Weight Chart


A8084C-1106

Important!

Keep a record of what you ship, and when you send it.

4.1 Transporting the Crane4.1.1 PARTIALLY DISASSEMBLE THE CRANE into components that can be

transported.

4.1.2 PACK THE CRANE for transport, using the original packaging materials, if appropriate.

4.1.3 PACK THE WINCH for transport, using the original packaging materials, if appropriate. Please see the winch owners manual for instructions.

4.1.4 REASSEMBLE THE CRANE at its new location following the instructions under Section 1.2 Assembling the Crane.

4.1.5 INSPECT THE CRANE according to the Instructions for Frequent Inspec-tion before installing it for operation. See Section 3.3.3 Instructions for Fre-quent Inspection.

4.2 Storing the Crane4.2.1 PARTIALLY DISASSEMBLE THE CRANE and store all parts in a cool

clean place away from corrosive chemicals and moisture.

4.2.2 SEAL THE CRANE in plastic with a desiccant to help protect it from rust, corrosion, and other damage.

4.2.3 SEAL THE WINCH in plastic with a desiccant to help protect it from rust, corrosion, and other damage. Please see the winch owners manual for in-structions.

4.2.4 REASSEMBLE THE CRANE at its new location following the instructions under Assembling the Crane.

4.2.5 INSPECT THE CRANE according to Section 3.3.4 Instructions for Periodic Inspection before installing it for operation.


A8084C-1106

5110 Series 5110GAL Series 5110SS Series5110 Series Portable Davit Cranes Red Fusibond Galvanized Finish Stainless Steelitem description part number qty. part number qty. part number qty.1 MAST C3857RED 1 C3857GAL 1 C3834 12 BOOM D2558RED 1 D2558GAL 1 D2553 13 BOOM EXTENSION C3858RED 1 C3858GAL 1 C3835 14 COTTER PIN .125 X 1.250 A4305 1 A4305 1 A4305 15 CLEVIS PIN .750 X 1.765 A4438 1 A4438 1 A4438 16 COTTER PIN .188/.250 X .042 DIA A6452 1 A6452 1 A6452 17 CLEVIS PIN .250 X 1.734 A6905 1 A6905 1 A6905 18 SHEAVE ASSEMBLY B2462 1 B2462 1 B2462 19 CLEVIS PIN .500 X 3.766 A8082 1 A8082 1 A8082 110 LYNCH PIN A7256 5 A7256 5 A7256 511 CLEVIS PIN .750 X 4.625 A7257 1 A7257 1 A7257 112 CLEVIS PIN .906 X 2.875 A7259 2 A7259 2 A7259 213 CLEVIS PIN .625 X 2.500 A7260 1 A7260 1 A7260 114 RATCHET JACK C3410 1 C3411 1 C3411 115 HANDLE B3561RED 1 B3561GAL 1 B3844 116 WARNING LABEL A1961 1 A1961 1 A1961 117 IMPORTANT INSERT PIN LABEL A2188 8 A2188 8 A2188 818 LOAD RATING LABEL A8083 1 A8083 1 A8083 119 THERN LOGO A6889 1 A6889 1 A6889 120 NAMEPLATE SST A1976 1 A1976 1 A1976 1

76

16

811 10 9

4 5

1310

14

15

1

17

19

17

1210

2

17 18

20

17

3

for winch and fasteners see page 20-21

10


A8084C-1106

5124 Series 5124GAL Series 5124SS Series5124 Series Portable Davit Cranes Red Fusibond Galvanized Finish Stainless Steelitem description part number qty. part number qty. part number qty.1 MAST C3385RED 1 C3385GAL 1 C3608 12 BOOM D2049RED 1 D2049GAL 1 D2270 13 BOOM EXTENSION C3386RED 1 C3386GAL 1 C3609 14 COTTER PIN .125 X 1.250 A4305 1 A4305 1 A4305 15 CLEVIS PIN .750 X 1.765 A4438 1 A4438 1 A4438 16 COTTER PIN .188/.250 X .042 DIA A6452 1 A6452 1 A6452 17 CLEVIS PIN .250 X 1.734 A6631 1 A6631 1 A6631 18 SHEAVE ASSEMBLY B2462 1 B2462 1 B2462 19 CLEVIS PIN .750 X 4.625 A7257 1 A7257 1 A7257 110 LYNCH PIN A7256 5 A7256 5 A7256 511 CLEVIS PIN 1.250 X 5.500 A7258 1 A7258 1 A7258 112 CLEVIS PIN .906 X 2.875 A7259 2 A7259 2 A7259 213 CLEVIS PIN .625 X 2.500 A7260 1 A7260 1 A7260 114 RATCHET JACK C3410 1 C3411 1 C3411 115 HANDLE B3561RED 1 B3561GAL 1 B3844 116 WARNING LABEL A1961 1 A1961 1 A1961 117 IMPORTANT INSERT PIN LABEL A2188 8 A2188 8 A2188 818 LOAD RATING LABEL A7261 1 A7261 1 A7261 119 THERN LOGO A6889 1 A6889 1 A6889 120 NAMEPLATE SST A1976 1 A1976 1 A1976 1

89101011

for winch and fasteners see page 20-21

1

2 3

12 1013 10

14

15 16

17

201819

4 5

6 7


A8084C-1106

1

23

23

11

23

5110M1 and 5110M3 Series 5110M2 Series 5110E2 Series5124M1 and 5124M3 Series 5124M2 Series 5124E2 Series

5110M1 Series 5110M2 Series 5110M3 Series 5110E2 Series5110 and 5124 Series Winch 5124M1 Series 5124M2 Series 5124M3 Series 5124E2 Seriesitem description part number qty. part number qty. part number qty. part number qty.1 WINCH M4312PB-K 1 4WM2-K 1 M4312PBSS-K 1 4WP2-K 12 CAPSCREW HEXHD A3355 4 A3355 4 A3355 4 A3355 43 HEX NUT A3356 4 A3356 4 A3356 4 A3356 4

1

3

4

5

2

5124 Series Two Part Line Option Model 5124TPLitem description part number qty.1 Clevis Pin A4438 12 Cotter Pin A4305 13 Swivel 5/16 Chain Size A7306 14 Snatch Block with Hook A4779 15 Latch Kit A9028 1


A8084C-1106

5110E4 5110E4GAL 5110E4SS 5124E4 5124E4GAL 5124E4SS5110E4 and 5124E4 Series Winch Red Fusibond Galvanized Finish Stainless Steelitem description part number qty. part number qty. part number qty.1 POWER WINCH 4777-K 1 4777-K 1 4777-K 12 MOUNTING PLATE ASSEMBLY C3114 1 C3114GAL 1 C3114 1 2a MOUNTING PLATE C3111RED 1 C3111GAL 1 C3111RED 1 2b CAPSCREW HEXHD .375-16NC X .750 A2975 4 A2975 4 A2975 4 2c WASHER HELSPRLK .375 X .683 X .094 A2926 4 A2926 4 A2926 4 2d CAPSCREW HEXHD .312-18NC X 2.000 A5042 6 A5042 6 A5042 6 2e HEX NUT NYLK .312-18NC A2927 6 A2927 6 A2927 6 2f FLAT WASHER SAE .312 X .688 X .065 A2924 6 A2924 6 A2924 6

2a

2d 2e 2f

2b 2c

5110E4DC 5110E4DCGAL 5110E4DCSS 5124E4DC 5124E4DCGAL 5124E4DCSS5110E4DC and 5124E4DC Series Winch Red Fusibond Galvanized Finish Stainless Steelitem description part number qty. part number qty. part number qty.1 POWER WINCH 4777DC-K 1 4777DC-K 1 4777DC-K 12 MOUNTING PLATE ASSEMBLY C3114 1 C3114GAL 1 C3114 1 2a MOUNTING PLATE C3111RED 1 C3111GAL 1 C3111RED 1 2b CAPSCREW HEXHD .375-16NC X .750 A2975 4 A2975 4 A2975 4 2c WASHER HELSPRLK .375 X .683 X .094 A2926 4 A2926 4 A2926 4 2d CAPSCREW HEXHD .312-18NC X 2.000 A5042 6 A5042 6 A5042 6 2e HEX NUT NYLK .312-18NC A2927 6 A2927 6 A2927 6 2f FLAT WASHER SAE .312 X .688 X .065 A2924 6 A2924 6 A2924 63 CONTROL BRACKET B3126 1 B3126 1 B3126 14 CAPSCREW SOXHD .250-20NC X 1.000 A4233 4 A4233 4 A4233 45 HEX NUT NYLK .250-20NC A2963 4 A2963 4 A2963 46 FLAT WASHER A4270 4 A4270 4 A4270 4

1

2

3

654

1

2

5110E4 Series 5110E4DC Series C3114 Mounting 5124E4 Series 5124E4DC Series Plate Assembly


A8084C-1106

Pedestal Base 510 Series 510 510GAL 510SSitem description part number qty part number qty part number qty1 BASE C3876 1 C3876 1 C3840 12 FLANGE BEARING B2450 1 B2450 1 B2450 1

510 and 524 Series Pedestal Base

12

Wall Base 510W Series 510W 510WGAL 510SSWitem description part number qty part number qty part number qty1 BASE C3880 1 C3880 1 C3846 12 FLANGE BEARING B2450 1 B2450 1 B2450 1

Socket Base 510F Series 510F 510FGAL 510SSFitem description part number qty part number qty part number qty1 BASE C3878 1 C3878 1 C3843 12 FLANGE BEARING B2450 1 B2450 1 B2450 1

Pedestal Base 524 Series 524 524GAL 524SSitem description part number qty part number qty part number qty1 BASE C3399 1 C3399 1 C3602 12 FLANGE BEARING B3565 1 B3565 1 B3565 1

Wall Base 524W Series 524W 524WGAL 524SSWitem description part number qty part number qty part number qty1 BASE C3407 1 C3407 1 C3804 12 FLANGE BEARING B3565 1 B3565 1 B3565 1

Socket Base 524F Series 524F 524FGAL 524SSFitem description part number qty part number qty part number qty1 BASE C3402 1 C3402 1 C3616 12 FLANGE BEARING B3565 1 B3565 1 B3565 1

1

2

510W and 524W Series Wall Base

2

1

510W and 524W Series Socket Base


A8084C-1106

5110 Series Performance Characteristics 2wire load rating for 5110M1 and M3 load rating for 5110M2, E2, E4, and E4DC lift belowrope wire rope position 1 position 2 position 3 position 4 position 1 position 2 position 3 position 4 fl oor leveldia. length (min max)1

1/4 in 20 ft 1000 lb 700 lb 600 lb 500 lb 1000 lb 700 lb 600 lb 500 lb 1 5 ft1/4 in 28 ft 1000 lb 700 lb 600 lb 500 lb 1000 lb 700 lb 600 lb 500 lb 9 13 ft1/4 in 36 ft 1000 lb 700 lb 600 lb 500 lb 1000 lb 700 lb 600 lb 500 lb 17 21 ft1/4 in 45 ft 1000 lb 700 lb 600 lb 500 lb 1000 lb 700 lb 600 lb 500 lb 26 30 ft1/4 in 60 ft 1000 lb 700 lb 600 lb 500 lb 1000 lb 700 lb 600 lb 500 lb 41 45 ft1/4 in 75 ft 1000 lb 700 lb 600 lb 500 lb 56 60 ft

12

34

B

A

lift belowfloor level

5124 Series Performance Characteristics 2wire load rating for 5124M1 and M3 load rating for 5124M2, E2, E4, and E4DC lift belowrope wire rope position 1 position 2 position 3 position 4 position 1 position 2 position 3 position 4 fl oor leveldia. length (min max)1

1/4 in 20 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb 0 4 ft1/4 in 28 ft 1800 lb 1600 lb 1300 lb 1000 lb 1700 lb 1600 lb 1300 lb 1000 lb 8 12 ft1/4 in 36 ft 1600 lb 1600 lb 1300 lb 1000 lb 1600 lb 1600 lb 1300 lb 1000 lb 16 20 ft1/4 in 45 ft 1600 lb 1600 lb 1300 lb 1000 lb 1500 lb 1500 lb 1300 lb 1000 lb 25 29 ft1/4 in 60 ft 1300 lb 1300 lb 1300 lb 1000 lb 1300 lb 1300 lb 1300 lb 1000 lb 40 44 ft1/4 in 75 ft 1200 lb 1200 lb 1200 lb 1000 lb 55 59 ft5/16 in 20 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb 0 4 ft5/16 in 28 ft 1700 lb 1600 lb 1300 lb 1000 lb 1600 lb 1600 lb 1300 lb 1000 lb 8 12 ft5/16 in 36 ft 1500 lb 1500 lb 1300 lb 1000 lb 1400 lb 1400 lb 1300 lb 1000 lb 16 20 ft5/16 in 45 ft 1400 lb 1400 lb 1300 lb 1000 lb 1400 lb 1400 lb 1300 lb 1000 lb 25 29 ft

5124 Series with 5124TPL Two-Part Line Kit Performance Characteristics 2wire load rating for 5124M1 and M3 load rating for 5124M2, E2, E4, and E4DC lift belowrope wire rope position 1 position 2 position 3 position 4 position 1 position 2 position 3 position 4 fl oor leveldia. length (min max)1

1/4 in 20 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb -3 1 ft1/4 in 28 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb 1 5 ft1/4 in 36 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb 5 9 ft1/4 in 45 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb 9 13 ft1/4 in 60 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb 17 20 ft1/4 in 75 ft 2000 lb 1600 lb 1300 lb 1000 lb 25 28 ft5/16 in 20 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb -3 1 ft5/16 in 28 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb 1 5 ft5/16 in 36 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb 5 9 ft5/16 in 45 ft 2000 lb 1600 lb 1300 lb 1000 lb 2000 lb 1600 lb 1300 lb 1000 lb 9 13 ft

1 Lift below fl oor level varies depending on boom position and base confi guration. For longer lifts, please contact factory.2 Performance Characteristics are for standard products referred to in this manual. Non- standard products may vary from the original design. Contact Thern, Inc. for this information.

Thern, Incorporated5712 Industrial Park RoadWinona, MN 55987

PHN 507-454-2996FAX 507-454-5282

EMAIL: [email protected]

lifting crane_om thern 5110_5124

Documents

product information

implied warranty

consequential damages

date of purchase

consequential costs

spon si bil i

spon si bil i

factory authorized repair